Cold spray technology for transportation applications: a process with impact

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Cold spray technology for transportation applications: a process with

impact

COLD SPRAY TECHNOLOGY FOR

TRANSPORTATION APPLICATIONS:

A PROCESS WITH IMPACT

D. Poirier, P. Vo, F. Nadeau, B. Guerreiro,

J.G. Legoux, E. Irissou

Cold Spray (CS)

2

Non-molten powder particles are

propelled by a supersonic gas jet and

sprayed onto a substrate where they

plastically deform to generate a coating.

http://dipi-platform.enise.fr/coldspray.html

Tranportation industry:

The challenges of vehicule lightweighting

3

www.truckvandetoekomst.nl

• Lightweight materials make a significant contribution to lowering emissions of

greenhouse gases. This concept still stands true in vehicle electrification as the

actual overall car’s weight are high (2150kg for the Mustang Mach E; 2490kg for

the Audi e-tron).

• Several manufacturing challenges are related to vehicule lightweighting.

• Adoption of light-weighting strategies are typically

costly reaching 0.5$/lb using high strength steels and

up to 1.5-2.0$/lb using aluminum alloys;

• The introduction of these materials is not as simple as

‘remove and replace’ which dictates an assessment of

the manufacturing feasibility for design concept and

material selection for the right application

Coating

Process

Dense coatings from a

variety of materials

showing high integrity

and excellent adhesion

Performance

Enhancement of

Light Metals

Additive

Manufacturing

Production of complex

shapes without limit in

thickness or in term of

final part size and

at high buildup rates

Structural

Reinforcement

Localized

Metal Addition

Addition of a dissimilar

material without HAZ

and with fair resolution

Welding of Dissimilar

Materials

Cold Spray in the transportation

industry

PERFORMANCE ENHANCEMENT OF

LIGHT METALS: LIGHT WEIGHT

BRAKES

Light Weight Brakes

Substitution of steel/cast iron with Al

6

Besides aluminum-based metal matrix

composites, other alternatives, including a

variety of protective coatings, have also been

considered but all presented problems in

terms of coating debonding, performance,

compatibility with current pads, costs and/or

productivity…

Pros

Cons

(N. Natarajan, Vijayarangan & Rajendran, 2006; Daoud & Abou El-khair, 2010, Aranke, Algenaid, Awe & Joshi, 2019).

Aluminum-based metal matrix composites

(MMC)

Performance Enhancement of Light

metals: a commercial example

7

Thermally-sprayed Fe-based coatings on the surface of Al engine cylinder bores:

• Thermally stable and easily machinable coatings at low cost with easy integration in

manufacturing facilities

• Specific application of rotors is more demanding, requiring the thermal spray

coatings to withstand the harsh mechanical and thermal stresses involved during

braking, including thermal cycling, as well as to resist to corrosion in atmospheric

conditions…

Plasma Sulzer/WW

Twin-Wire arc

Heller/Daimler

Wire Arc Plasma Flame

Spray/Ford

Main challenge:

Coating adhesion

requirements

Duplex

Coating

NRC Duplex Fe-based Coating

8

Arc sprayed layer

Cold sprayed layer

Al 356

500 µ m

Poirier, D., Irissou, E., Legoux, J.G., Gallant, D., Bi-layer iron

coating of lightweight metallic substrate WO2015186095A1

Cold Spray

bond coat

• High adhesion

• High density

Arc-sprayed

top coat

• Superior wear

performance

• Productivity

Performance Enhancement of Light

metals: Light Weight Brakes

9

Coating

Adhesion (MPa)

# cycles before spalling

Arc

39*

1,620

Duplex M

58**

>10,000

• High adhesion on aluminum A356 and high

resistance to thermal cycling

• Enhanced protection against corrosion by

inhibiting blistering and debonding

• Excellent wear resistance

Coating

Material

Wear rate

(10

_mm

_/m)

COF

Gray cast

iron

1.3 ± 0.2

0.36

Bulk SS304

45 ± 25

0.72

CS

4.8 ± 1.7

0.38

Duplex SA

0.75 ± 0.07

0.42

*failure at the coating/substrate interface

**failure between the cold spray and the arc spray layers

REF Poirier, D., Legoux, J.G., Irissou, E., Gallant, D., Jiang,

J. (2019). Development of Protective Thermal Spray Coatings

for Lightweight Al Brake Rotor Discs, JTST, 28, 291-304.

ADDITIVE MANUFACTURING;

STRUCTURAL REINFORCEMENT

Structural Reinforcement

11

• Panels used for vehicle structures present uneven stress distribution

due to structural discontinuities.

• The option to locally reinforce the panels rather than thickening them

evenly can significantly reduce panel weight. However, such

additions can cause assembly problems and can even worsen stress

states.

Cold spray

Advantages

Challenges

• continuous/even bonding of the

reinforcement

• no assembly steps

• much more flexibility in term of

reinforcement pattern

• deposit ductility, especially for aluminum

alloys

• complex geometries with shape fidelity

require development of build strategies and

toolpath planning

Improvement of Deposit Ductility

12

•

While Al deposits cold sprayed using nitrogen present reasonable

strength levels, ductility, deposition efficiency and bond strength to the

substrate remain low, even after HT.

•

Powder modification as a novel approach:

•

Elemental blends drastically improves cold spray deposition.

•

Deposit compositions can be controlled through the fine tuning of

initial feedstock and that

•

Microstructures can be homogenised after heat treatment

•

Work done at NRC and elsewhere shows that standard or tailored solid

solution and ageing heat treatments can be performed on Al cold spray

deposit to complete deposit mechanical properties optimisation.

(Rokni, Widener, Champagne, Crawford & Nutt, 2017; Widener, Ozdemir, Carter 2018).

Al 7075-type, coating as-sprayed

After HT@550°C for 5h in air

Production of complex geometries

13

Adaptation of the conventional AM build up strategy

(layer-by-layer build) for CS;

Wall feature, before and after machining

More complex shapes  further

development in term of intersection

handling and thermal management

Build-up strategy

1 3

2

LOCALIZED METAL ADDITION

TECHNIQUE; WELDING OF

DISSIMILAR MATERIALS

Welding of Dissimilar Materials

15

•

Mechanical fastening or solid-state joining processes commonly used.

•

Friction stir welding  intermetallic compound thickness as well as tool

NRC New Friction Stir Welding Lap

Joint Technique

16

Pure aluminum tierce material cold sprayed on the surface of the hard steel.

Tool pin protruding into the cold spray deposit

Amira, Gougeon , Legoux & Nadeau, Joined incompatible

metallic parts and method of joining, US20180221985A1

Results

17

• High travel speeds (ranging

from 4-5m/min) obtained

• Decent lap shear tensile

strength (390N/mm of weld

length) making the joint

failed in the heat affected

zone (HAZ) for Usibor 1500

steel and 201LN ¼ hard

stainless steel

2.0mm thick AA6022-T4 friction stir lap welded to

1.85mm thick Usibor 1500 boron steel using a pure

aluminium cold spray deposit; post-joint paint-baking

process reaching T6 showing a HAZ lap shear failure

Conclusion

18

Cold spray is a flexible manufacturing technique for which several promising

applications have been identified within the transportation industry.

C

oa

tin

g

P

ro

ce

ss

• Production of

dense and

adherent

coatings for the

performance

enhancement

of light metals

A

dd

iti

ve

M

an

uf

ac

tu

rin

g

_{• Build up of}

thick structural

reinforcements

of complex

geometry on

large panels

Lo

ca

liz

ed

M

et

al

A

dd

iti

on

• Addition of

transition layers

to allow the

friction stir

welding of

dissimilar

materials

REFERENCES

19

Amira S., Gougeon P., Legoux, J.G., Nadeau F., Joined incompatible metallic parts and method of joining US20180221985A1.

Aranke, O., Algenaid, W., Awe S., Joshi, S. (2019). Coatings for Automotive Gray Cast Iron Brake Discs: A Review, Coatings, 9 (9), 552.

Daoud, A., Abou El-khair, M.T. (2010). Wear and Friction Behavior of Sand Cast Brake Rotor Made of A359-20vol% SiC Particle Composites Sliding Against Automobile Friction Material, Tribology International, 43, 544-553.

Deptula L., Noah A. (2015), Estimating the Cost Impact of Lightweighting Automotive Closures, SAE International.

Farley, G. (2004). Selective reinforcement to enhance the structural performance of metallic compression panels, Proceedings of the Structures, Structural Dynamics & Materials Conference, Palm Spring, California.

Murinathinam C., Vimalathithan S.A. et al. (2013), Design and Manufacturing Challenges of High Strength Steel in Automotive Light Weighting, SAE International.

Natarajan, N., Vijayarangan, S., Rajendran, I. (2006). Wear Behavior of A356/25SiCp Aluminum Matrix Composites Sliding Against Automobile Friction Material, Wear, 261, 812–822.

Poirier, D., Legoux, J.G., Irissou, E., Gallant, D., Jiang, J. (2019). Development of Protective Thermal Spray Coatings for Lightweight Al Brake Rotor Discs, Journal of Thermal Spray and Technology, 28, 291-304.

Poirier, D., Irissou, E., Legoux, J.G., Gallant, D., Bi-layer iron coating of lightweight metallic substrate WO2015186095A1

Popoola, O.O., Zaluzec, M.J., McCune, R.C. (1998). Novel Powertrain Applications of Thermal Spray Coatings, Surface Engineering, 14 (2), 107-112. Spinella D.J. (2013). Common Joining Methods Used in Aluminum Structures, Alcoa Technical Center, United States.

Rokni, M.R., Widener C.A., Champagne, V.K., Crawford, G.A., Nutt, S.R. (2017). The effects of heat treatment on 7075 Al cold spray deposits, Surface and Coatings Technology, 310, 278-285

Vo, P., Martin, M. (2017). Layer-by-layer buildup strategy for cold spray additive manufacturing, Proceedings of the Internal Thermal Spray Conference, Dusseldorf, Germany. Widener, C.A., Ozdemir, O.C., Carter M. (2018). Structural repair using cold spray technology for enhanced sustainability of high value assets, Procedia Manufacturing, 21, 361-368

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